Capsule for preparing consumable product

ABSTRACT

A capsule is provided for use in a machine for preparing product from capsules. The capsule includes a body that defines an interior space with an opening at one location and an aperture at another location. A soluble closure is disposed on an interior surface of the body to cover the aperture. Ingredients are disposed within the interior space for preparing a desired product. A cover is disposed over the opening and a removable cover is disposed over the aperture. The removable cover is removed from capsule prior to insertion of capsule into the machine. The soluble closure is adapted to dissolve upon exposure to fluid from the capsule machine in order to allow prepared product to exit capsule through aperture. In another embodiment, a delivery system such as a soluble pouch or a film containing ingredients is disposed in the capsule.

FIELD

This specification relates to consumable products and in particular tocapsules for preparing a consumable product.

BACKGROUND

The following background discussion is not an admission that anythingdiscussed below is citable as prior art or common general knowledge. Thedocuments listed below are incorporated herein in their entirety by thisreference to them.

Single serve capsules for use in machines to prepare a desiredconsumable product are becoming increasingly popular. Such capsules comein a variety of formats most typically for producing beverages such asespresso coffee, drip coffee, tea, hot chocolate or soup broth.

Capsule machines typically include an injection system for injecting afluid, such as hot water, into a capsule for mixing with ingredientsdisposed within the capsule. A dispensing system is also provided todispense the prepared product from the capsule for delivery to areceptacle such as a user's cup or bowl. The dispensing system may forinstance comprise a hollow probe that is adapted to pierce the capsuleand allow product to flow through the probe from the capsule fordelivery to a desired receptacle.

A problem with conventional single serve capsules and capsule machinesis that they are not adapted for use with insoluble consumableingredients. Such ingredients will not easily flow through conventionaldispensing systems such as those with hollow narrow diameter probes inorder that they may be deposited into the desired receptacle forconsumption by a user. For example, vegetables and noodles for a soupproduct will not flow through a conventional hollow probe dispensingsystem for a capsule machine.

Another problem with conventional single serve capsules is that they arenot adapted for separating ingredients within the capsule in a costeffective manner to meet regulatory standards or other productrequirements. For example, it may be desirable to prepare a product fromtwo or more ingredients that must be kept separate from one anotherwithin the capsule until the preparation stage. The ingredients mayinclude dry ingredients and wet ingredients that may not be mixed untilthe preparation stage. Or the ingredients may include an activeingredient that reacts in the presence of another ingredient. Or theingredients may include an additive that must be separated from otheringredients and be delivered directly into a cup for improving efficacy.

Another problem with conventional single serve capsules is that they arenot adapted for dispensing product to a desired receptacle withoutexposing portions of the capsule machine to contamination by thedispensed product. This is a problem when the residue from the dispensedproduct comes into contact with subsequent products prepared with thecapsule machine. This can impact flavors and can also present a healthrisk when the dispensed product contains ingredients that may be harmfulto others (such as regulated drugs, alcohol or ingredients that may bean allergy risk such as a peanut allergy).

There is a need for an improved capsule for use in a capsule machinethat addresses one or more problems with conventional capsules such asthose listed above.

SUMMARY

In one aspect the invention provides a capsule, for use in a machine forpreparing consumable products from capsules, said capsule comprising:

a body defining an interior space with an opening at one location and anaperture at another location;a soluble closure disposed in said body for closing said aperture;ingredients disposed in said interior space for preparing a desiredproduct;a cover disposed over said opening; anda removable cover disposed on an exterior surface of said body over saidaperture.

In another aspect the invention provides a capsule, for use in a machinefor preparing consumable products from capsules, said capsulecomprising:

a body defining an interior space with an opening at one location and anaperture at another location;a soluble delivery system disposed in said body, said soluble deliverysystem containing ingredients for preparing a desired product;a cover disposed over said opening; anda removable cover disposed on an exterior surface of said body over saidaperture.

Other aspects and features of the teachings disclosed herein will becomeapparent, to those ordinarily skilled in the art, upon review of thefollowing description of the specific examples of the specification.

DRAWINGS

The drawings included herewith are for illustrating various examples ofarticles, methods, and apparatuses of the present specification and arenot intended to limit the scope of what is taught in any way. Forsimplicity and clarity of illustration, where considered appropriate,reference numerals may be repeated among the drawings to indicatecorresponding or analogous elements.

FIG. 1 is a schematic view of a capsule in accordance with the presentinvention being loaded into a capsule machine for preparing a consumableproduct;

FIG. 2 is a vertical sectional view of another embodiment of capsule inaccordance with the present invention;

FIG. 3( a) is a vertical sectional view of another embodiment of capsulein accordance with the present invention, the capsule having an exitnozzle disposed in a retracted position;

FIG. 3( b) is a vertical sectional view of the capsule as shown in FIG.3( a), with the exit nozzle disposed in an extended position;

FIG. 4( a) is a vertical sectional view of another embodiment of capsulein accordance with the present invention;

FIG. 4( b) is a perspective view of a conical insert for use with thecapsule shown in FIG. 4( a);

FIG. 5 is a vertical sectional view of another embodiment of capsule inaccordance with the present invention;

FIG. 6 is a vertical sectional view of another embodiment of capsule inaccordance with the present invention; and

FIG. 7 is a schematic enlarged sectional view of the dispensing systemfor the capsule shown in FIG. 6.

DESCRIPTION OF VARIOUS EMBODIMENTS

Various apparatuses or methods will be described below to provideexamples of the claimed invention. The claimed invention is not limitedto apparatuses or methods having all of the features of any oneapparatus or method described below or to features common to multiple orall of the apparatuses described below. The claimed invention may residein a combination or sub-combination of the apparatus elements or methodsteps described below. It is possible that an apparatus or methoddescribed below is not an example of the claimed invention. Theapplicant(s), inventor(s) and/or owner(s) reserve all rights in anyinvention disclosed in an apparatus or method described below that isnot claimed in this document and do not abandon, disclaim or dedicate tothe public any such invention by its disclosure in this document.

A single serve capsule in accordance with the present invention is showngenerally at 10 in the figures. Capsule 10 includes a body 12, filter 14(when required), ingredients 16 and cover 18.

Ingredients 16 may include soluble and insoluble ingredients. Insolubleingredients may include consumable ingredients 16 a (ingredients, suchas noodles and dried vegetables, that are intended to be consumed aspart of the prepared product) and non-consumable ingredients 16 b(ingredients, such as tea leaves, coffee grounds, herbs or otherflavoring ingredients, that are not intended to be consumed as part ofthe prepared product). Ingredients 16 may include active ingredients (egfoaming agents), natural health additives, regulated drugs, alcohol orother desired ingredients.

Capsule 10 is sized and configured for use in a machine 20 that isadapted for preparing a product from capsule 10. Capsule may be formedin any shape that is adapted to fit within a corresponding capsulechamber disposed in machine 20. Machine 20 may include an injectionsystem 22 for injecting a fluid, typically heated water, into thecapsule for mixing with ingredients 16. Injection system 22 may includea nozzle 22 a disposed on machine 20 that is adapted to pierce cover 18to inject fluid into capsule 10. Injection system 22 may alternativelyhave at least one component disposed on capsule 10, such as on cover 18,and adapted to pierce body 12 and interact with machine 20 to injectfluid into capsule 10.

Machine may also include a dispensing system 24 for dispensing productfrom capsule 10 into a desired receptacle 26 such as a bowl or cup.Dispensing system 24 may include a hollow probe 24 a that is adapted topierce capsule 10 to dispense a prepared product from capsule 10.Dispensing system 24 may further include a collection chamber 24 b andexit port 24 c, downstream from hollow probe 24 a for collecting anddispensing prepared product into receptacle 26.

Capsule 10 may be configured to avoid interaction with hollow probe 24 afor use in cases where a conventional hollow probe 24 a is not adaptedfor dispensing insoluble consumable ingredients 16 a. Such ingredients16 a may become clogged within the small diameter channel defined inhollow probe 24 a.

Body 12 of capsule 10 includes a sidewall 30 and an end wall 32 togetherdefining an interior space 34. Sidewall 30 has a first portion 30 a anda second portion 30 b. Second portion 30 b is configured to avoidcontact with dispensing system 24 when capsule is disposed in machine20. Second portion may thus taper inwardly from first portion 30 a toend wall 32 sufficiently to avoid contact with dispensing system 24.

An opening 36 is defined at one end of body 12 and a flange 38 extendsaround the perimeter of opening 36.

Filter 14 is adapted to be disposed within body 12 to define at leastone ingredients chamber within interior space 34 for receiving one ormore ingredients 16 and in particular non-consumable ingredients 16 b.Filter 14 may be secured to flange 38 or to an interior surface ofcapsule 10 (such as to sidewall 30). Capsule 10 may be provided withoutfilter 14 in instances where ingredients are soluble or where it isdesired that ingredients 16 are dispensed together with fluid intoreceptacle 26 (as shown in FIG. 2).

Cover 18 is disposed over opening 36 and secured to body 12 such as bysealing cover 18 directly to flange 38 or indirectly with a portion offilter 14 located between.

An aperture 40 is defined in end wall 32 for dispensing product fromcapsule. Aperture 40 is sized to allow product including consumableingredients 16 a to pass through aperture 40 without clogging.Preferably aperture 40 has a diameter in the range of 5-50 mm, morepreferably 10-30 mm and most preferably 15-25 mm.

Second portion 30 b of side wall 30 tapers inwardly from first portion30 a to aperture 40. Second portion 30 b thus directs product withincapsule 10, including consumable insoluble ingredients 16 a, towardaperture 40.

A soluble closure 42 is provided to close aperture 40 to preventconsumable ingredients 16 a from passing through aperture 40 until fluidis injected into capsule. Soluble closure 42 may be formed of any foodsafe (edible) soluble material that is suitable for preventingingredients from passing through aperture 40 until the desired time.

Soluble closure 42 may for example be in the form of a membrane (asshown in FIGS. 1, 2 and 4) that covers aperture 40 or in the form of aplug (as shown in FIGS. 3( a) and 3(b)) that is disposed within aperture40. When closure 42 is in the form of a membrane it may be sealed to aninterior surface of capsule 10 around the perimeter of aperture 40 usingsuitable sealing materials such as polyethylene or polypropylene. Whenclosure 42 is in the form of a plug it may be sized to fit snugly withinaperture 40 with or without the aid of a similar sealing material. Aplug is best suited for use when aperture 40 comprises an elongatepassage.

Closure 42 is adapted to dissolve upon exposure to fluid within apredetermined time. In some instances, it is preferable that there is adelay in the dissolution of closure 42 in order to allow the fluid andingredients 16 to mix and steep to extract flavor or functionalcomponents prior to dispensing product from capsule 10. This isparticularly desirable when certain ingredients are non-consumableinsoluble ingredients contained within filter 14. In such instances, itis desirable that fluid is contained within capsule 10 and permitted tomix with ingredients and steep for a pre-determined time. The rate ofdissolution of closure 42 may be determined/programmed at least in partby parameters of closure 42 such as thickness, density and composition(molecular weight and chemistry) as well as external factors such asfluid temperature and internal pressure.

Preferred materials for soluble closure 42 include protein orcarbohydrate based materials which could be starch based (e.g., amylosefilm and amylopectin film), protein based (e.g., gelatin film, caseinfilm), polysaccharide based (e.g., pullulan film, cellulose film),alginate sodium film and pectin film, to name a few. For example, theVivos™ edible water soluble film from MonoSol™ can be employed as amembrane form of closure 42 in this application. As mentioned earlier,the dissolution rate of a soluble closure is dependent on the materialtype. Within the same type, the dissolution rate is normally slower whenhaving heavier material density or molecular weight. Preferably theclosure 42 thickness is in the range of 10-100 μm, more preferably 20-80μm and most preferably 30-70 μm.

Soluble closure 42 may also be formed from ingredients 16. Anagglomeration of soluble and/or insoluble consumable ingredients 16 a ontheir own or with a food safe binder material, similar to a bouilloncube, may for instance be formed into a plug that is disposed withinaperture 40.

A removable cover 44, preferably formed of a multilayered material thatincludes a barrier layer (preferably adapted to act as a barrier for oneor more of moisture, oxygen, and light), is disposed over aperture 40 onan exterior surface of capsule 10 to provide a barrier seal foringredients 16 within capsule 10. Removable cover 44 may include a tab46 that may be gripped by a user to peel away removable cover 44 andexpose aperture 40. It will be understood that closure 42 continues tocover aperture 40 following removal of cover 44 until use of capsule 10in machine 20.

During use, a user will remove cover 44 from capsule 10 and insertcapsule into a corresponding capsule chamber within machine 20. Machine20 is activated by the user in order that injection system 22 injectsfluid, such as heated water, into capsule 10. Fluid mixes withingredients 16 and dissolves closure 42. Upon dissolution of closure 42,aperture 40 is exposed and product (fluid plus extract fromnon-consumable ingredients 16 a, if applicable, plus insolubleconsumable ingredients 16 b) is allowed to pass through aperture 40 intodesired receptacle 26.

Alternative embodiments of capsule 10 are described with reference toFIGS. 2-7 below. Similar reference numerals are used to refer to similarelements as the embodiment discussed above.

Referring to FIG. 2, another embodiment of capsule 10 is shown. In thisembodiment, capsule 10 does not include filter 14 or non-consumableingredients 16 b.

Referring to FIGS. 3( a) and 3(b), another embodiment of capsule 10 isshown. In this embodiment, capsule 10 does not include filter 14 ornon-consumable ingredients 16 b. Capsule 10 further includes an exitnozzle 50 that is disposed in aperture 40 and adapted to be moved from aretracted position, prior to removal of cover 44, to an extendedposition, following removal of cover 44. In its extended position, exitnozzle 50 provides a clean disposable surface for product to flowthrough exit port 24 c of machine 20 to receptacle 26.

Exit nozzle 50 defines an aperture 52 that is closed by closure 42. Inthis embodiment, closure 42 is in the form of a plug that is disposed inexit nozzle 50. Exit nozzle 50 further includes a shoulder 54 that isadapted to prevent exit nozzle 50 from falling through aperture 40.

In a variation of this embodiment, capsule 10 may be provided with exitnozzle 50 that is fixed in an extended position. Exit nozzle 50 andcover 44 may have corresponding threads (not shown) to allow cover 44 tobe removably and threadably attached to exit nozzle 50. Exit nozzle 50may alternatively have a closed end and be adapted to be broken, cutopen or pierced to expose aperture 52.

Referring to FIG. 4( a), another embodiment of capsule 10 is shown. Inthis embodiment, capsule 10 has a conventional shape similar to capsules10 used for preparing beverage products. A conical insert 60 (as shownin isolation in FIG. 4( b)) is disposed within capsule 10 to definesecond portion 30 b of side wall 30 for directing product to aperture40. Conical insert may be secured in place with a sealing material orother suitable attachment means. Conical insert 60 is sized to avoidcontact with dispensing system 24. As a result, dispensing system 24,such as probe 24 a may puncture end wall 32 of capsule 10 withoutcontacting second portion 30 b of sidewall 30. The advantage of theembodiment depicted in FIG. 4( a) is that the capsule resembles aconventional capsule and also has a flat base defined by end wall 32 toallow capsule 10 to rest on a flat surface prior to use.

Referring to FIG. 5, another embodiment of capsule 10 is shown. In thisembodiment, at least some consumable ingredients 16 a are containedwithin a soluble delivery system 70 in the form of a pouch 72.Ingredients 16 may include liquid ingredients (such as a concentrate) orother ingredients that must be kept separated within capsule (such asfoaming agents or other active ingredients). Soluble and insolubleconsumable ingredients 16 a may all be contained within a singledelivery system 70 or may be separated into a plurality of deliverysystems 70. Non-consumable ingredients 16 b may be contained separatelywithin capsule 10 in a chamber defined by filter 14. Soluble closure 42is not required for this embodiment if all loose ingredients arecontained within delivery system 70. Soluble closure 42 may still beprovided however in instances where certain consumable ingredients 16 aare not contained within soluble delivery system 70. Soluble closure 42may also be provided as an added control over the dwell time of fluidwithin capsule prior to dispensing as discussed above.

Soluble delivery system 70 may be made of similar food safe materials asdescribed above for soluble closure 42. Delivery system 70 is adapted todissolve when fluid is injected into capsule 10. The rate at whichdelivery system 70 dissolves may be determined at least in part byparameters of delivery system 70 such as thickness, density andcomposition as well as external factors such as fluid temperature andinternal pressure.

Referring to FIGS. 6 and 7, capsule 10 may include an alternate deliverysystem 70 in the form of a soluble film 80 comprising one or more layers82 of ingredients 16 tied together with a soluble binder 84. A solubleprotective layer 86 may be provided to protect certain ingredients 16contained within capsule 10 from exposure to other ingredients 16contained within film 80. Protective layer 86 may also protectingredients 16 contained within film 80 from external elements duringprocessing and handling. Protective layer 86 may have desired barrierproperties to maintain the stability of ingredients 16 contained withinfilm 80 until protective layer 86 is dissolved.

Film 80 may be disposed in capsule 10 for the purpose of addingmicrodoses of desired additives such as flavor, health or medicinalingredients or active agents. In the case of certain sensitiveadditives, such as medicinal additives, film 80 may be formed at a thirdparty manufacturing facility that meets the regulatory requirements forproducing such ingredients and then delivered to a facility formanufacturing capsules 10.

While the above description provides examples of one or more processesor apparatuses, it will be appreciated that other processes orapparatuses may be within the scope of the accompanying claims.

I/We claim:
 1. A capsule, for use in a machine for preparing consumableproducts from capsules, said capsule comprising: a body defining aninterior space with an opening at one location and an aperture atanother location; a soluble closure disposed in said body for closingsaid aperture; ingredients disposed in said interior space for preparinga desired product; a cover disposed over said opening; and a removablecover disposed on an exterior surface of said body over said aperture.2. The capsule of claim 1, wherein said body includes a side wall thattapers inwardly from said opening to said aperture.
 3. The capsule ofclaim 2, wherein said side wall has a first portion that extends fromsaid opening to a second portion, said second portion tapering inwardlyfrom said first portion to said aperture.
 4. The capsule of claim 1wherein said ingredients include insoluble consumable ingredients. 5.The capsule of claim 4 wherein said ingredients include noodles.
 6. Thecapsule of claim 4 wherein said ingredients include dried vegetables. 7.The capsule of claim 1 further comprising a filter disposed in said bodyfor filtering at least some of said ingredients.
 8. The capsule of claim7, wherein said filter defines a first chamber containing insolublenon-consumable ingredients.
 9. The capsule of claim 1 further comprisingan exit nozzle disposed in said aperture, said exit nozzle being adaptedfor directing the consumable product from said capsule to a desiredreceptacle without the consumable product contacting the machine. 10.The capsule of claim 9 wherein said exit nozzle is adapted to move froma retracted position to an extended position.
 11. The capsule of claim 1further comprising an insert disposed in said interior space, saidinsert being adapted for directing the consumable product to saidaperture.
 12. The capsule of claim 1 further comprising a solubledelivery system disposed in said body, said soluble delivery systemcontaining at least some ingredients for preparing a desired product.13. The capsule of claim 12 wherein said soluble delivery systemcomprises a soluble pouch containing at least some ingredients.
 14. Thecapsule of claim 12 wherein said soluble delivery system comprises asoluble film comprising one or more layers containing at least someingredients.
 15. The capsule of claim 12 wherein said soluble filmincludes a protective layer adapted to protect certain ingredientsdisposed in said film from exposure to other ingredients disposed insaid capsule.
 16. A capsule, for use in a machine for preparingconsumable products from capsules, said capsule comprising: a bodydefining an interior space with an opening at one location and anaperture at another location; a soluble delivery system disposed in saidbody, said soluble delivery system containing ingredients for preparinga desired product; a cover disposed over said opening; and a removablecover disposed on an exterior surface of said body over said aperture.17. The capsule of claim 16, wherein said body includes a side wall thattapers inwardly from said opening to said aperture.
 18. The capsule ofclaim 17, wherein said side wall has a first portion that extends fromsaid opening to a second portion, said second portion tapering inwardlyfrom said first portion to said aperture.
 19. The capsule of claim 16wherein said ingredients contained in said soluble delivery systeminclude soluble consumable ingredients.
 20. The capsule of claim 16further comprising a filter disposed in said body, wherein said filterdefines a chamber containing insoluble non-consumable ingredients forpreparing a desired product.
 21. The capsule of claim 16 wherein saidsoluble delivery system comprises a soluble pouch containing at leastsome ingredients.
 22. The capsule of claim 16 wherein said solubledelivery system comprises a soluble film comprising one or more layerscontaining at least some ingredients.
 23. The capsule of claim 16wherein said soluble film includes a protective layer adapted to protectcertain ingredients disposed in said film from exposure to otheringredients disposed in said capsule.